DIN EN 14587-2-2009 Railway applications - Track - Flash butt welding of rails - Part 2 New R220 R260 R260Mn and R350HT grade rails by mobile welding machines at sites other than a.pdf

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1、August 2009DEUTSCHE NORM English price group 18No part of this standard may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 25.160.10; 93.100!$Y96“

2、1542219www.din.deDDIN EN 14587-2Railway applications Track Flash butt welding of rails Part 2: New R220, R260, R260Mn andR350HT grade rails by mobile welding machines at sites other than afixed plantEnglish version of DIN EN 14587-2:2009-08Bahnanwendungen Oberbau Abbrennstumpfschweien von Schienen T

3、eil 2: Abbrennstumpfschweien neuerSchienen der Stahlsorten R220, R260, R260Mn und R350HT durch mobileSchweimaschinen an Orten auerhalb eines SchweiwerkesEnglische Fassung DIN EN 14587-2:2009-08www.beuth.deDocument comprises pages42DIN EN 14587-2:2009-08 Start of validity This standard takes effect o

4、n 1 August 2009. National foreword This standard has been prepared by Technical Committee CEN/TC 256 “Railway applications” (Secretariat: DIN, Germany). The responsible German body involved in its preparation was the Normenausschuss Fahrweg und Schienenfahrzeuge (Railway Standards Committee), Techni

5、cal Committee NA 087-00-01-01 AK Schienen- schweien. 2 EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 14587-2April 2009ICS 25.160.10; 93.100English VersionRailway applications - Track - Flash butt welding of rails - Part 2:New R220, R260, R260Mn and R350HT grade rails by mobilewelding machines at

6、 sites other than a fixed plantApplications ferroviaires - Voie - Soudage des rails partincelage - Partie 2: Rails neufs de nuance R220, R260,R260Mn et R350HT par des machines de soudure mobilesdans des sites autres quune installation fixeBahnanwendugen - Oberbau - Abbrennstumpfschweienvon Schienen

7、- Teil 2: Abbrennstumpfschweien neuerSchienen der Stahlsorte R220, R260, R260Mn undR350HT durch mobile Schweimaschinen an Ortenauerhalb eines SchweiwerkesThis European Standard was approved by CEN on 28 February 2009.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which sti

8、pulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard e

9、xists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards b

10、odies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUR

11、OPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: Avenue Marnix 17, B-1000 Brussels 2009 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 14587-2:2009: EEN 14587-2:2009 (

12、E) 2 Contents Page Foreword 4 Introduction .5 1 Scope 6 2 Normative references 6 3 Terms and definitions .6 4 Requirements for the welding process .8 4.1 General 8 4.2 Clamping force .8 4.3 Pre-heating flashing .8 4.4 Progressive flashing .8 4.5 Upsetting 8 4.6 Upset current 8 4.7 Unclamping 8 4.8 W

13、elding program and records 8 4.9 Step across the weld .9 4.10 Weld trimming . 10 4.11 Post-weld heat treatment . 11 5 Procedure approval of a MFBW machine . 12 5.1 General . 12 5.2 Sample preparation 12 5.3 Approval tests . 12 5.3.1 Visual inspection 12 5.3.2 Weld trimming and upset examination . 12

14、 5.3.3 Step across the weld 12 5.3.4 Magnetic particle or dye penetrant inspection 12 5.3.5 Bend testing 13 5.3.6 Macro examination . 13 5.3.7 Micro examination 13 5.3.8 Hardness testing . 13 5.3.9 Fatigue testing 14 5.4 Test result report 14 6 Approval of other rail profiles or grade 14 6.1 General

15、 . 14 6.2 Approval tests . 14 6.2.1 General . 14 6.2.2 Grade R220 14 6.2.3 Grade R260Mn . 14 6.2.4 Grade R350HT . 14 7 Approval of the Welding Contractor . 15 7.1 General . 15 7.2 Requirements for initial approval 15 7.2.1 Welding procedure . 15 7.2.2 Quality systems 15 7.2.3 Information to be provi

16、ded by the contractor 15 7.2.4 Operators . 15 7.2.5 Supervision . 15 7.2.6 Weld Inspection 15 7.2.7 Equipment . 16 7.3 Field approval of the welding contractor . 16 7.4 Audits . 16 DIN EN 14587-2:2009-08 3 8 Weld production and acceptance requirements 16 8.1 Information from the purchaser . 16 8.2 S

17、ite preparation of rail ends . 16 8.3 Rail alignment 17 8.4 Weld parameter monitoring 17 8.5 Weld identification . 17 8.6 Visual inspection . 17 8.7 Steps across the weld . 17 8.8 Profile finishing of the rail head . 18 8.8.1 Initial grinding 18 8.8.2 Final grinding . 18 8.9 Geometrical acceptance c

18、riteria 18 8.10 Weld production testing 19 8.10.1 General 19 8.10.2 Additional test requirements 19 8.10.3 Bend test 19 8.10.4 Interpretation of results 20 8.11 Documentation . 20 Annex A (normative) Bend test requirements 21 Annex B (normative) Test weld fracture faces Recording of defects . 23 Ann

19、ex C (normative) Fatigue test method for flash butt welds 25 Annex D (normative) Macro examination and micro examination . 34 Annex E (normative) Hardness testing . 35 Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC 36 Bibl

20、iography 40 DIN EN 14587-2:2009-08 EN 14587-2:2009 (E) EN 14587-2:2009 (E) 4 Foreword This document (EN 14587-2:2009) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national st

21、andard, either by publication of an identical text or by endorsement, at the latest by October 2009, and conflicting national standards shall be withdrawn at the latest by October 2009. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent righ

22、ts. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document is one of a series of three parts of the EN 14587 “Railway applications Track Flash butt welding of rails”. The list of parts is as follows: Part 1: New R220, R260, R260Mn and R350HT gra

23、de rails in a fixed plant; Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant; Part 3: Welding in association with crossing construction. This document has been prepared under a mandate given to CEN by the European Commission and the Eu

24、ropean Free Trade Association, and supports essential requirements of EC Directive(s). For relationship with EC Directive(s), see informative Annex ZA, which is an integral part of this document. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following

25、 countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia

26、, Spain, Sweden, Switzerland and the United Kingdom. DIN EN 14587-2:2009-08 5 Introduction This part of EN 14587 has three main topics: a) approval procedure for a mobile flash butt welding (MFBW) machine; b) approval of the welding contractor; c) weld production. This part of EN 14587 has been occa

27、sioned by a European Directive that will permit the freedom of an open European market. To enable this perception to become a reality, it is essential a standard is in place that satisfies the needs of the infrastructure owners or custodians and reflects the production capabilities of the manufactur

28、ers in technical and quality terms. This part of EN 14587 differs from Part 1 significantly due to the peculiarities of a MFBW machine: they are used at different places and for different purchasers within a short time; they work in various conditions such as weather, rail, track, worksites, power s

29、upply, legal regulations; they are operated by contractors, but personnel from different companies (including the purchaser) may be on site for the production of the continuous welded track; there are technical differences of the equipment used in order to guarantee the required mobility. Due to the

30、 above mentioned special operating conditions of a MFBW machine, the following requirements have been relaxed as a result: minimum bend test requirements for production bend tests only; maximum permitted trimmed upset. This part of EN 14587 does not identify any approval of a MFBW machine in terms o

31、f electromagnetic compatibility, vehicle braking systems or any requirements regarding load gauge, environment and its attendant issues or infrastructure access pertaining to any railway authority. DIN EN 14587-2:2009-08 EN 14587-2:2009 (E) EN 14587-2:2009 (E) 6 1 Scope This European Standard specif

32、ies requirements for the approval of a welding process by a MFBW machine at sites other than fixed plant, as well as the welding contractor together with the requirements for subsequent welding production. Where a MFBW machine is to be used in a static but temporary situation, the requirements of th

33、is part of the standard shall apply. It applies to new Vignole R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a MFBW machine at sites other than a fixed plant and intended for use on railway infrastructures. This European Standard applies to the

34、 welding of rails into welded strings. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendmen

35、ts) applies. EN 571-1, Non destructive testing Penetrant testing Part 1: General principles EN 1290, Non-destructive examination of welds Magnetic particle examination of welds EN 13674-1, Railway applications Track Rail Part 1: Vignole railway rails 46 kg/m and above EN 14587-1, Railway application

36、s Track Flash butt welding of rails Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant EN ISO 6507-1, Metallic materials Vickers hardness test Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1, Metallic materials Verification of static uniaxial testing machines Part 1: Tension/

37、compression testing machines Verification and calibration of the force-measuring system (ISO 7500-1:2004) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 fixed plant stationary production line for flash butt welding of rails, as specified by

38、EN 14587-1 3.2 welding process any part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 3.3 upset metal extruded around the rail profile as a result of forging 3.4 die burn damage caused by localised overheating on the surface of the rail

39、 caused by poor contact between the rail and the electrode during welding DIN EN 14587-2:2009-08 7 3.5 trimming removal of upset 3.6 trimmed upset metal remaining around the rail profile following trimming 3.7 dressing removing trimmed upset by grinding or other similar process 3.8 as welded conditi

40、on rails that have been welded and trimmed only 3.9 profile finishing operation by which the rail head or relevant part of the rail head at the weld is returned to rail profile NOTE The operation can be by grinding, milling, planing or any other suitable means. 3.10 finished condition welded, trimme

41、d, dressed and profile finished 3.11 flat spot process driven discontinuity showing as a small lens-like shape in vertical longitudinal section, or a generally circular/elliptical shape having a localised smooth texture when viewed in a vertical transverse section 3.12 lack of bond area of incomplet

42、e fusion between the rails in the joint NOTE This may appear as crack like or line discontinuity at the interface either on the surface after removal of the upset or in a weld section. 3.13 welded string long rail comprising a number of shorter rails flash butt welded together 3.14 MFBW machine abbr

43、eviation for a mobile flash butt welding machine 3.15 purchaser purchaser of the welds 3.16 railway authority (RA) either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.17 contractor company approved by a

44、 RA to provide staff and machinery to execute the production of mobile flash butt welds on that particular infrastructure NOTE This may include staff and machinery from within the RA. DIN EN 14587-2:2009-08 EN 14587-2:2009 (E) EN 14587-2:2009 (E) 8 3.18 manufacturer manufacturer of the welding machi

45、ne 4 Requirements for the welding process 4.1 General All welding shall be carried out on a MFBW machine using an automatic, programmed welding sequence. 4.2 Clamping force Rails shall be secured in the MFBW machine by clamps of such a surface shape or contour, that when a clamping force is exerted

46、on the rails, it shall not damage the rail in such a way that subsequent cracking in the rail in operation is generated. 4.3 Pre-heating flashing The fronts of the heated area shall progress uniformly perpendicularly to the running surface during the whole cycle. There shall be no evidence of overhe

47、ating on the ends of the rails during pre-heating flashing. Once initiated, the flashing process shall not be interrupted. 4.4 Progressive flashing Once initiated, progressive flashing shall be continuous. 4.5 Upsetting Upsetting shall immediately follow flashing. Sufficient forging pressure shall b

48、e applied to ensure that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The weld interface shall extend into the upset. 4.6 Upset current The upset welding current shall be maintained until the rapid forge has finished and the progressive forging

49、 commences. 4.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. 4.8 Welding program and records The welding program (settings) shall be determined during procedural trials and, once approval has been granted, shall not be changed. The welding machine and/or management system equipment shall be capable of displaying the following: a) welding program identification and setting details; b) welding current; c) upset force or pres